Method of making a cast in place wall



Sept. 24, 1968 K. GUDDAI. 3,402,522

METHOD OF MAKING A CAST 1N PLACE WALL Filed May 2l, 1965 3 Sheets-Sheet l INVENTOR. KARL. GUDDAI.

'ATTORNEYS Sept. 24, 1968 K. GUDDAI.

- METHOD OF MAKING A CAST IN PLACE WALL 3 sheetghee,C 2

Filed May 21 1965 FIGH Ef- NW Sept. 24, 1968 K. GUDDAL METHOD OF MAKING A CAST IN PLACE WALL 3 Sheets-Sheet 5 Filed May 2l, 1965 NVENTOR KARL GLJDDAI.`

ATTO R NEYS United States Patent O 3,402,522 METHOD F MAKING A CAST IN PLACE WALL Karl Guddal, Peger Road, Fairbanks, Alaska 99701 Continuation-in-part of application Ser. No. 381,318, July 9, 1964. This application May 21, 1965, Ser. No. 457,611

2 Claims. (Cl. 52-741) This application is a continuation-in-part of my application Ser. No. 381,318, now Patent No. 3,364,640, tiled July 9, 1964.

This invention relates in general to a wall construction for a building and method of making same, and more particularly to a building stud for use in wall construction of a building, and still more particularly to a building stud capable of giving guidance to the construction of a wall.

The building stud of the present invention is especially useful for reinforcing walls primarily constructed of cementitious material, including concrete, cement mortar and the like. Preferably, the building stud is of steel, although it may be of any other suitable material capable of providing suitable reinforcement for cementitious material. It should also be appreciated that while the stud of the present invention will be described and illustrated for wall construction, such wall construction includes vertical and horizontal panels and thus could be employed for ceiling and floor construction.

The wall construction of the present invention includes the use of a plurality of building studs arranged in spaced coplanar relationship and embedded in concrete to provide a concrete reinforced wall structure. The method of making the wall construction involves erecting a plurality of spaced coplanar building studs, all of one configuration or of mixed configurations, anchoring the studs at their opposite ends, and embedding the studs in concrete. If the wall construction is to be vertical, the studs would be anchored at the bottom against displacement from a predetermined position such as by a plate having holes therein for receiving the lower ends of the studs, and at the top by a bracket engaging the upper end of the studs and suitably supported to hold its position. The concrete may be applied by positioning forms about the studs and pouring into the forms, or by pneumatic placement where a backing member (form or sheet of insulation) is secured along one side of the studs and the concrete is applied from the other side by being propelled against the studs and backing member. In the latter case, the studs form support for the concrete as it is applied to hold it in place.

In one embodiment of the invention, a building stud adapted to be embedded in concrete includes reinforcing bar means having a web or truss means secured thereto for guiding the placement of a preiinished panel or a panel of insulation or just a temporary form panel so that the bar means is spaced therefrom and can be then completely embedded in the concrete material. It should also be appreciated that the reference to concrete herein is intended to refer to any suitable cementitious material for use in building construction.

Inanother embodiment of the invention, a screed or border bar may be attached to the web or truss for deiining a guide to adjust the thickness of a wall so that the wall may be maintained straight and plumb, and so that uniform thickness can be obtained.

It is therefore an object of the present invention to provide a new and improved wall construction and method of making same.

A further object of the invention is to provide a new and improved building stud for Wall construction.

Another object of this invention resides in the provision of a building stud for wall construction that is capable of providing a guide for wall thickness and for the placement of a backing panel so that the main reinforcing bars of the stud can be completely embedded in concrete material.

Still another object of this invention is to provide a building stud for wall structures that is capable of giving a Wall greater strength and additional lire protection.

A further object of this invention is to provide a building stud for wall construction that is capable of enhancing the construction of the wall when employed with concrete, wherein the stud includes means for guiding the uniform thickness of the wall and to enhance the plumbing of the wall surface.

A still further object of this invention is to provide a wall construction including building studs and cementitious material that is more economical to construct than heretofore reinforced cementitious material structures, and which provides materially greater strength.

Other objects, features and advantages of the invention will be apparent from the following detailed disclosure, taken in conjunction with the accompanying sheets of drawings, wherein like reference numerals refer to like parts, in which:

FIG. 1 is a fragmentary vertical sectional view taken through a wall employing a building stud in accordance with the present invention;

FIG. 2 is a fragmentary horizontal sectional view of the wall of FIG. 1, taken substantially along lines 2 2 thereof;

FIG. 3 is a horizontal sectional view like that of FIG. 2 but illustrating a modification wherein only a pair of spaced vertical bar members are employed;

FIG. 4 is a fragmentary vertical sectional View of a wall embodying a further modification of the building stud according to the present invention wherein only a single vertical bar is provided;

FIG. 5 is a fragmentary horizontal sectional view taken substantially along line 5-5 of FIG. 4;

FIG. 6 is a fragmentary vertical sectional view taken through a wall and illustrating a further modied building stud according to the present invention that includes screed or border bars for aiding in the construction of the wall to a uniform thickness;

FIG. 7 is a fragmentary horizontal sectional View taken substantially along line 7-7 of FIG. 6;

FIG. 8 is a fragmentary vertical sectional view taken through a wall and is a further modification of a building stud according to the present invention and particularly a modification of the stud shown in FIGS. 6 and 7, wherein only a single vertical member and screed bar is shown;

FIG. 9 is a fragmentary ihorizontal sectional view taken substantially along line 9-9 of FIG. 8;

FIG. 10 is a fragmentary vertical sectional view taken through a wall and illustrating a still further modification of the present invention;

FIG. 1l is a cross-sectional view showing a building stud according to the invention constructed similarly to the building stud of FIG. 4 but positioned closer to one side ofthe wall than the other;

FIG. l2 is a perspective view of a wall construction in accordance with the present invention showing some parts cut away and others removed for purposes of clarity;

FIG. 13 is a side elevational view of the bracket arrangement yfor supporting a building stud in erected vertical position during the construction of the wall;

FIG. 14 is a perspective view, somewhat diagrammatic, illustrating a building stud arrangement different from that shown in FIG. 12;

FIG. 15 is a view similar to FIG. 14 but showing still another arrangement of building studs for a wall construction according to the present invention; and

FIG. 16 is a view similar to FIGS. 14 and 15 but illustrating still another arrangement of building studs for the wall construction of the present invention.

Referring now to the drawings, and paritcularly to FIGS. 1 and 2, a wall is shown including a building stud 15 having a panel 16 at one side wherein the stud is embedded in concrete 17.

The stud 15 includes a pair of inner verticaly arranged reinforcing bars 18 in substantially parallel spaced relationship with a pair of outer vertically arranged reinforcing bars 19. A sinuously shaped web or chord 20 extends between the spaced bars 18 and 19 and also between each of the bars 18 and each of the bars 19. The web or truss 20 is suitably secured to the bars 18 such as by welding or the like so that the bars 18 and 19 and the web 20 essentialy comprise an integral unit. The web 20 may be of any desired cross-sectional configuration such as circular as shown and is arranged so that the portions thereof secured to the bars 18 do not extend beyond the outer edges thereof, while at the same time the portions secured to the bars 19 are arranged to extend beyond the outer edges thereof to define extensions 21 that serve to space the panel 16 a distance from the bars 19. It can be appreciated that the extension 21 may be made greater or smaller depending upon the distance desired for spacing the panel 16 from the bars 19. The vertical reinforcing bars 18 and 19 may also take any desired cross-sectional configuration although they are shown circular in the present drawings.

The panel 16 may be of insulated material if it is desired to be an outside wall surface or it may be of a prefinished material if it is to be an interior wall surface. Any suitable means (not shown) may be employed for securing the upper and loWer ends of the stud 15 in a self-supporting manner prior to the mounting of the panel 16 and the application of the concrete 17. As in conventional wall construction, it will be appreciated that the studs 15 would be spaced along the wall any desired distance in order to obtain the strength of the wall desired and to accommodate the particular sizes of the panel 16. Further, the spacing of the bars 18 and 19 may be adjusted in accordance with the desired thickness of the wall and the reinforcing desired. It should be further appreciated that the concrete 17 may be applied in any suitable manner such as pneumatically or otherwise.

Hence, it can be seen that 'the bars 19 will be spaced from the palnel 16 by means of the spacing extensions 21 so that the bars 19 are completely embedded in the concrete and thereby enhance the overall strength of the wall and provide greater fire resistance. Quite obviously, the bars 19 can therefore function as better reinforcing members since they are embedded in the concrete 17.

Referring now to FIG. 3, a modified building stud 22 is shown which differs from the stud 15 only in that a single vertically arranged reinforcing bar 23 is provided on one side of the stud and a single vertically arranged reinforcing bar 24 is provided on the other side of the stud, both ofwhich are secured together by means of a web 25. It will be appreciated that any number of vertical bars may be employed in any one building stud.

The embodiment of FIGS. 4 and 5 differs from the previous embodiments only in that the building stud 26 includes a single vertically arranged reinforcing bar 27 having a web 28 secured to one side thereof for spacing the panel 16 from the bar 27. This stud would be employed where a thinner wall structure could be used.

The embodiment of FIGS. 6 and 7 illustrates a building stud 29 having pairs of parallel spaced vertically arranged reinforcing bars 30 and 31 interconnected by a sinuously shaped web or truss 32. In this embodiment, the web 32 includes spacing extensions 33 extending beyond the bars 30 and spacing extensions 34 extending beyond the bars 31. The web 32 is suitably secured to the bars 30 and 31 as in the previous embodiments. Vertically arranged screed or border bars 35 and 36 are suitably secured as by welding or otherwise to the extensions 33 and 34, respectively. Again, the reinforcing bars 3l) and 31 are embedded in the concrete 17 and the screed bars 35 and 36 define a guide for the thickness of the concrete and also serve as a guide to keep the inner and outer wall surfaces straight and plumb. Any suitable means may be provided for applying the concrete to the studs, such as by pneumatic application and wherein some lathing may be provided in the center of the wall to initially receive the first layers of concrete. In an actual Wall construction, the stud 29 may be alternately employed with the stud 15 or the stud 26 or any other stud as the screed guiding need not be on every stud.

Referring now to FIGS. 8 and 9, a modification of the stud of FIGS. 6 and 7 is shown wherein the stud, generally indicated by the numeral 37, includes a single vertically arranged reinforcing bar 38 having a sinuously shaped web 39 extending from one side thereof. A screed or border bar 40 is secured to the web 39. In this embodiment, it would not be critical as to the plumbing of the concrete surface on one side but it would be desired to have a guide on the side having the screed bar 40.

Referring now to the embodiment of FIG. l0, a stud 41 is shown which combines the features of the studs of FIGS. 1-5 and the studs of FIGS. 69, wherein the stud is capable of providing a guide for the positioning of the paneling 16 on one side and for the guidance of the wall thickness and plumbing on the other side. This stud includes vertically arranged reinforcing bars 42 and 43 interconnected by a web or truss 44 having spacing extensions 45 extending from the bar 42 and spacing extensions 46 extending from the bar 43. The spacing extensions 46 serve to space the paneling 16 from the vertical reinforcing bar 43, while a screed or border bar 47 is suitably secured to the spacing extensions 45 for the purpose of guiding the thickness of the wall and the thickness of the concrete beyond the bar 42. This stud, like the stud 29, may also be alternately employed in a wall structure with any of the other studs shown.

It should be appreciated in all of the embodiments, the reinforcing bars and webs are suitably interconnected by welding or the like and that where screed bars are provided, they are also connected by welding or the like to the webs. Further, while the webs or trusses are illustrated as being sinuously shaped, it should be appreciated that they may take other forms so long as they provide means for interconnecting the spaced reinforcing bars or so long as they provide spacing extensions for spacing the paneling or for having secured thereto screed or border bars.

The embodiment of FIG. 11 differs from the embodiment of FIG. 4 primarily in that the wall construction includes a building stud 48 that is positioned within the concrete 17 closer to one side of the wall. In this embodiment, the building stud 48 includes a reinforcing bar 48a having a web or truss member 48b suitably connected thereto by welding or the like and which serves to space the reinforcing bar 48a from the backing panel or sheet 16 during the formation of the Wall and the application of the concrete 17. It should be appreciated that in some instances, the strength given to the concrete wall by a building stud will be more desirous along one side of the wall than the other side because of the use put to the wall structure. Thus, the placement of the building stud 48 could be at any position between the opposite sides of the wall structure as long as it is embedded within the concrete 17.

Referring now to FIGS. 12 and 13, a wall structure according to the present invention is illustrated including the manner of positioning and supporting the building studs 22 during construction of the wall. This arrangement includes a bottom plate or anchor member 49 and a plurality of bra-ckets 50. The building studs 22 are suitably spaced along the anchor member 49 and means is provided to prevent displacement of the lower ends of the studs. For example, openings 51 may be provided in the anchor member 49 to receive the lower ends of the reinforcing bars 23 and 24 of the stud so that the lower end of the stud is anchored or positively positioned relative to the anchor member 49 and relative to adjacent studs. Alternately, fastening members may be shown to secure the lower ends of the vertical reinforcing bars of the building stud in position along the anchor member 49. Further, the planes of the building studs would extend substantially perpendicularly to the anchor member 49. It should be appreciated that any other suitable means may be provided to hold the lower ends of the building studs in position.

The upper ends of the building studs 22 are held in position by the brackets 50' which include a bar 51 having a pair of socket members 52 secured thereto for receiving therein the upper ends of the vertical reinforcing bars 23 and 24 of the building stud 22. One end of the bar 5-1 extends beyond the .area of the wall structure and is anchored to a ground post 53 by a connecting bar 54. It should be appreciated that any suitable bracket and positioning means may be employed which engages the upper ends of the studs 22 and is suitably anchored with respect to the anchor member 49* to properly hold the vertical studs 22 in position during construction of the wall. After the wall has been fully constructed, the brackets 50 may then be removed as the wall will then be self-supporting.

As seen in FIG. l2, the forming member 16 which may be a sheet of insulation or removable after the Wall has been completely constructed is attached to the webs 25 of the studs by means of fasteners 55. Following the anchoring of the building studs at the upper and lower ends by the brackets and anchor member, and the securing of the backing sheet 16 to the building st-uds, the concrete 17 may then be applied pneumatically. Application of the concrete 17 in accordance with the invention would alternately be by blowing the concrete in ldense form againstthe building studs and backing member 16 until the concrete is of the desired thickness to embed the building studs. The concrete is blown on first at the lower ends of the studs and then gradually up to the top, wherein the building studs serve as supporting members for the concrete as it is applied. This is the preferable manner of constructing this wall structure, although the use of another form opposite to the member 1-6 would enable pouring of the concrete between the forms and about the building studs.

Referring now to FIG. 14, a modified building stud arangement for the wall structure of the present invention is illustrated wherein the placement of building studs 26 between building studs 22 serves to reduce the building Vstud cost Where possible. This illustrates that it is not necessary to make the wall construction of the present invention with building studs of the same type thro-ughout its length. Thus, the structure of FIG. 14 shows the alternate usage of building studs 22 and 26. In this embodiment, it can be appreciated that the brackets 56 for `supporting the upper ends of the building studs 26 merely differ from the brackets 50* in that only a single socket is employed for anchoring the upper ends of the building studs 26 that .are provided with only a single vertical reinforcing bar.

The embodiment of FIG. differs from the embodiment of FIG. 14 only in that the building stud employed between adjacent building studs 22 is of a di'erent configuration than the building stud 26 in FIG. 14. This building stud, designated by the numeral 57, merely comprises a single vertical reinforcing bar and is void of a truss or web for spacing of the stud from a side of the wall, this function being adequately accomplished by the building studs 22. It should be appreciated that the building stud 57 may be arranged at any desired depth 4in the wall structure depending upon the needs of the installation.

The embodiment of FIG. 16 illustrates the use of building studs arranged in horizontal position where it is necessary to provide further reinforcing in the wall structure along the longitudinal axis thereof. In this embodiment, a plurality of building studs 22 are arranged in vertical position and spaced longitudinally along the anchor member 49 and being suitably supported by brackets 50 at their upper ends. A top reinforcing horizontal stud 22A is positioned over the upper end of the building studs 22 and arranged so that its plane is normal to the vertical studs 22. In this embodiment, the reinforcing bar 23A is received along the inner sides of the vertical reinforcing bars 23 of the studs 22. Similarly, the reinforcing bar 24A may be received along the insides of the reinforcing bars 24 of the studs 22, while the web or truss 25A at the building studs may be looped around the vertical reinforcing bars 24. This horizontally arranged building stud 22A may have the reinforcing bars 23A and 24A spaced slightly closer together in order to t within the vertical reinforcing bars 23 and 24. Suitable lwires or other fasteners may be employed to temporarily position the building stud 22A along the upper ends of the building studs 22 while the concrete is being laid up.

If further longitudinal reinforcing is desired, the horizontal stud 58 may be employed anywhere along the vertical of the building studs 22. This stud would include parallel opposed reinforced bars S9 and 60 interconnected by a web or truss 61 that would merely be arranged to interconnect the bars 59 and 60. This horizontal building stud could be arranged between the opposed reinforcing bars 23 and 24 of the building studs 22 and thereafter be suitably fastened and held in position by wire or the like 62. It should be appreciated that either or both of the horizontal building studs 22A and 58 may be employed for further strengthening the wall structure with the buildring studs 22.

It will be understood that modifications and variations may be effected without departing from the scope of the novel concepts of the present invention, but it is understood that this application is to be limited only by the scope of the appended claims.

The invention is hereby claimed as follows:

1. The method of making an upstanding reinforced concrete panel including a plurality of building studs some of which include a pair of parallel reinforcing bars interconnected by a sinuous chord member having portions extending from one of the bars to guide construction of the panel and placement of the studs therein, said method comprising the steps of erecting a plurality of said building studs into upright coplanar and horizontally spaced relationship with the plane of the studs extending normal to the long axis of the panel, applying means to the lower ends of said studs to hold same against moveunent, applying removable means to the upper ends of said studs to hold same in position and against displacement, securing a sheet of imperforate rigid material to the sinuous chord member portions in spaced relation to the reinforcing bars along one side of the studs, and pneumatically applying concrete against the studs and sheet of material until the parallel reinforcing bars of the studs are completely embedded in the concrete.

2. The method as defined in claim 1, including the securing of a horizontally extending building stud to said upright studs before application of the concrete.

(References on following page) References Cited UNITED STATES PATENTS Pierson 52-694 Nicholas 52-648 Tashjian 52-334 Bradley 52-127 Jones et a1. 52-648 Goeltz 52-648 Inglee 52-694 Cory 25-131 Wilson 52-601 Holsman 52-694 Jester 52-408 Sersen 52-241 Garrett 52-383 Balduf 52-344 Terry. 52--251 FOREIGN PATENTS France.

10 FRANK L. ABBOTT, Primary Examiner.

J. L. RIDGILL, JR., Assistant Examiner. 

1. THE METHOD OF MAKING AN UPSTANDING REINFORCED CONCRETE PANEL INCLUDING A PLURALITY OF BUILDING STUDS SOME OF WHICH INCLUDE A PAIR OF PARALLEL REINFORCING BARS INTERCONNECTED BY A SINUOUS CHORD MEMBER HAVING PORTIONS EXTENDING FROM ONE OF THE BARS TO GUIDE CONSTRUCTION OF THE PANEL AND PLACEMENT OF THE STUDS THEREIN, SAID METHOD COMPRISING THE STEPS OF ERECTING A PLURALITY OF SAID BUILDING STUDS INTO UPRIGHT COPLANAR AND HORIZONTALLY SPACED RELATIONSHIP WITH THE PLANE OF THE STUDS EXTENDING NORMAL TO THE LONG AXIS OF THE PANEL, APPLYING MEANS TO THE LOWER ENDS OF SAID STUDS TO HOLD SAME AGAINST MOVEMENT, APPLYING REMOVABLE MEANS TO THE UPPER ENDS OF SAID STUDS TO HOLD SAME IN POSITION AND AGAINST DISPLACEMENT, SECURING A SHEET OF IMPERFORATE RIGID MATERIAL TO THE SINUOUS CHORD MEMBER PORTIONS IN SPACED RELATION TO THE REINFORCING BARS ALONG ONE SIDE OF THE STUDS, AND PNEUMATICALLY APPLYING CONCRETE AGAINST THE STUDS AND SHEET OF MATERIAL UNTIL THE PARALLEL REINFORCING BARS OF THE STUDS ARE COMPLETELY EMBEDDED IN THE CONCRETE. 